Reducing sulfur gas emissions resulting from the burning of carbonaceous fuels

ABSTRACT

A method of reducing sulfur emissions by applying remediation materials in a powder sorbent onto coal and combusting the coal with the materials applied. The powder sorbent contain sources of silicon, aluminum, calcium, iron, and magnesium, and ash from combustion contains the captured sulfur.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/631,046 filed on Dec. 28, 2006; which is the National Phase filing ofPCT/US2005/11881 filed on Apr. 8, 2005; which claims the benefit of U.S.Provisional Application No. 60/583,420 filed on Jun. 28, 2004, the fulldisclosure of which is hereby incorporated by reference.

INTRODUCTION

The present invention relates to processes and compositions fordecreasing emissions of sulfur gases upon combustion of carbonaceousmaterials. In particular, powder and liquid sorbent compositions areadded to coal to capture sulfur in the ash and prevent release of sulfuroxides into the atmosphere.

Cost effective energy sources necessary for sustaining economic growthand national well-being are becoming more difficult to identify anddevelop. Increasing costs of fuels such as oil, gas and propane have ledto an extensive examination of other available energy sources. Two ofthe most cost effective sources of energy are nuclear power and coalpower. Given public concerns with nuclear energy and its long-termdisposal challenges, more emphasis is being placed on coal-generatedpower.

Significant coal resources exist in the United States and elsewhere.According to some estimates, known reserves are capable of meeting largeportions of our energy needs into the next two centuries. In the UnitedStates, low BTU value coal is found in the Powder River Basin ofWyoming/Montana, lignite deposits in the north central region (North andSouth Dakota), sub-bituminous deposits of the East Pittsburgh seam inPennsylvania, Ohio and West Virginia, and bituminous coal is found inthe Illinois Basin. Except for the Powder River Basin coals, the UnitedStates coals tend to be characterized as having a high sulfur content.Although low sulfur coal can be shipped to other locations to provide arelatively clean burning fuel, it is more cost effective for utilitiesto burn locally produced coal. In most parts of the world this meansburning a higher sulfur coal to satisfy society's energy needs.

The burning of high sulfur coal releases a significant amount ofsulfur-containing gases, which can cause acid rain and other harmfuleffects if allowed to escape from the coal burning facility. Utilitiesand other coal consumers are constantly striving to reduce or eliminatethe amount of sulfur given off by power plants and coal powered boilers,in order to protect the environment and the health of its workers andcustomers. One effective strategy involves retrofitting older coalburning facilities with wet scrubbers for sulfur capture. Thesefacilities are typically large in size and consume up to 5% of theenergy generated by the plant. Although widely used, their cost isbecoming almost prohibitively expensive, which leads to rate hikes thatmust be borne ultimately by the consumer or rate payer.

An alternative to wet scrubbing for removal of sulfur is the applicationof sulfur sorbing and stabilizing materials to the coal. Much work hasbeen done in this area due to its ease of application and elimination ofhigh capital costs for equipment as needed in wet scrubbing operations.Application of sulfur sorbent directly to the coal has the advantage ofa long retention time with the furnace gases thus allowing for greatersulfur capture.

U.S. Pat. No. 4,824,441 by Kindig discusses several methods that havebeen tried in attempting to improve sulfur capture. Kelly, et al.,concluded (first joint symposium on Dry SO₂ and simultaneous SO₂/NO_(x)Control Technologies, EPA 600/9-85-020a, Paper no. 14, July 1985) thatsulfur sorbents should be injected downstream to avoid high peaktemperatures in the combustion zone. It was also suggested that theresidence time of calcium-based sorbents should be maximized in the1800-2250F.° zone of the furnace. Work conducted by Dykema (U.S. Pat.No. 4,807,542) suggests the use of silicon to help optimize sulfurcapture when combined with CaO as a remediation agent. Steinberg in U.S.Pat. Nos. 4,602,918 and 4,555,392 has suggested the use of Portlandcement as a sorbent for coal.

As these references indicate, there is a need for cost effectiveremediation of sulfur, nitrogen, mercury and chlorine resulting from thecombustion of coal. More efficient and less costly removal techniquesare still needed in order to effectively develop and utilize high sulfurcoal resources.

SUMMARY

In various embodiments, the invention provides a process for burningcoal or other carbonaceous fuels wherein sulfur and other undesirablecompounds are captured and retained in non-reactive ceramic-like formafter the combustion phase. In various embodiments, a variety of liquidand powder sorbents are added to the coal before combustion to removesulfur and other undesirable elements from the volatile combustionproducts.

In various embodiments, the process of the present invention involvesthe capture of sulfur in a calcium and ceramic based matrix utilizingmultiple element alkali powders and/or strongly oxidizing calcium andbromide based nitrates and nitrites. These remediation materials whenapplied in a complex powder containing multiple elements result insuperior sulfur capture than these elements would otherwise achieve onan individual basis. In some embodiments, the materials containbentonites and metakaolins, which will aid in raising the melting pointof the ash thus minimizing oxidation and decreasing ash toughness,adhesion, and slagging.

Powder sorbent compositions contain inorganic materials that providesources of silicon, aluminum, calcium, iron, and magnesium. In apreferred embodiment, the powder sorbent contains Portland cement,calcium oxide, optionally a clay, and a dolomitic material. It has beenfound that addition of the powder absorbent to coal before combustionmitigates or reduces the amount of sulfur gases produced during burningof the coal, or equivalently increases the amount of sulfur contained inthe ash after combustion. Advantageously, the sorbent may be added tothe coal at levels at up to six % by weight, avoiding large buildups ofash during combustion.

In various embodiments, powder sorbents are provided that reduce theamount of mercury and/or chlorine in the combustion gas as well as theamount of sulfur. Preferred powder sorbents for mitigation or reductionof mercury contain in addition to the metals indicated above a componentcomprising a water soluble chlorine containing inorganic compound.Additionally, the mercury sorbents preferably contain additionalcomponents selected from the group consisting of potassium and sodiumsilicates, hydroxides, and oxides. In a preferred embodiment, themercury sorbent contains Portland cement, sodium chloride, calciumoxide, metakaolin, and at least one alkali metal salt selected from thegroup consisting of silicates, hydroxides, and oxides.

In preferred embodiments, the respective powder sorbents furthercomprise components that contribute oxidizing anions to the sorbentcomposition. Preferred oxidizing anions include nitrates and nitrites.The oxidizing anions may be added in the form of calcium nitrate andcalcium nitrite, or as other oxidizing anion salts, depending on thelevel of calcium otherwise provided in sorbent composition and otherfactors.

The oxidizing anions may be added to the powder sorbent composition inthe form of solid inorganic salts. In a preferred embodiment, theoxidizing anions such as nitrites and nitrates are applied to the coalin a separate step. In a preferred embodiment, an aqueous solutioncomprising about 20% to 80% of inorganic salts comprising the oxidizinganions is applied to the coal. Preferably, the solution is applied tothe coal before a powder sorbent is applied.

In a preferred embodiment, a liquid sorbent comprising calcium or othersalts of nitrates and nitrites is applied to the coal. Thereafter, thepowder sorbent systems described above are applied to the wetted coal,to form a combustible coal composition. Alternatively, a liquid or solidsorbent composition containing calcium nitrate and calcium nitrite maybe added to the coal and the coal further combusted, with an observedreduction in the amount of sulfur gases being released into theatmosphere, while at the same time the amount of sulfur in the ash isobserved to increase.

The sorbents can be added directly to raw coal or to crushed andpulverized fuel. Liquid sorbents may be added through a spray bar systemadded directly to the fuel as it passes over a belt or other transportsystem. Alternatively, the liquid may be added into a mixer where thefuel is mixed with the liquid sorbent prior to combustion. The powdersorbents are preferably added to a crushed or pulverized fuel in a mixersystem prior to combustion. As discussed, in a preferred embodiment, thepowder sorbents are added to coal that has already been wetted with aliquid sorbent system. It is preferred to add the sorbents in such a wayas to maximize contact time between the sorbent and the fuel duringcombustion. This in turn will result in sintering of the calcium andsulfur elements in the boiler to a preferred extent. Conveniently,liquid sulfur sorbents are generally added in the ratio of sorbent tosulfur of between one and two. Such addition levels are generallysufficient to adsorb sulfur and fuels having sulfur content ranging fromabout 2% to about 4.5%. Typical additions comprise adding about 6% byweight of sorbent, related to the weight of the raw fuel feed.

In various embodiments, the process of the invention involves thecapture of sulfur in a calcium and ceramic based matrix utilizingmultiple element alkali powders, optionally together with oxidizinganions such as nitrates and nitrites, preferably based on calcium. Theremediation materials, when applied in a complex powder containingmultiple elements, result in higher sulfur capture than the materialswould otherwise achieve on an individual basis. In a preferredembodiment, the powder sorbents contain clays coupled with iron andother elements. It is believed that the presence of these elements actsto minimize or lower the melting point of the ash. This leads to loweredcohesiveness and toughness of the ash so that less ash builds up on theboiler and better heat transfer is obtained. This minimization ofslagging, or buildup of the ash on the boiler during combustion,provides advantages to the use of the compositions and processes of theinvention.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating some preferred embodiments of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

DESCRIPTION

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

In various embodiments, the invention provides liquid and powder sorbentcompositions and methods for applying them to carbonaceous fuel. Coal isa preferred carbonaceous fuel to use in embodiments of the invention.When coal or other carbonaceous fuel containing sulfur is burned, sulfurgases are released into the atmosphere. Likewise, if the coal or othercarbonaceous fuel contains chlorine or mercury, those elements may bereleased into the atmosphere. Because the sulfur, chlorine, and mercurythus released would otherwise pollute the atmosphere, it is desirable toprevent or reduce that release by use of liquid and powder sorbents ofthe invention.

By use of some of the embodiments of methods and compositions of theinvention, upon combustion of the carbonaceous fuel to release itsstored energy, the amount of sulfur gases in the combustion product isreduced, and the amount of sulfur in the ash is increased, relative tothe amount of sulfur gases and ash sulfur, respectively, that would beproduced by combustion of the carbonaceous fuel without applying theliquid and/or powder sorbent compositions of the invention.

The liquid and sorbent compositions of the invention contain a varietyof inorganic components that are sources of active elements andcompounds in the compositions. Some of the components are water solubleand are conveniently applied as part of a liquid sorbent composition.Other components of the sorbent compositions of the invention are waterinsoluble and are therefore preferably added as solids, or as part ofso-called powder compositions, to the carbonaceous fuel by a variety ofphysical processes, including mixing. In various embodiments it ispreferred to add both a liquid and a powder sorbent composition to thecarbonaceous fuel, to achieve the advantages of the invention discussedfurther below.

In other embodiments, combustible carbonaceous fuel compositions areprovided that are the product of the application or addition of thevarious powder and/or liquid sorbent compositions onto the carbonaceousfuel. In practicing the combustible carbonaceous fuel compositions ofthe invention, it is to be appreciated that the inorganic materialsapplied to the carbonaceous fuel to provide the compositions may beadded in a variety of ways, including application of various liquid andpowder sorbents of the invention.

In various preferred embodiments, compositions and methods of theinvention may be used to remediate or mitigate the amount of mercury andother harmful elements released into the atmosphere upon combustion ofcarbonaceous fuels. As discussed in further detail below, compositionsand methods that reduce the amount of mercury or chlorine emitted aremade and practiced in essentially the same way as for those compositionsthat are more directly drawn to sulfur gas remediation.

In one embodiment, the invention provides a method of applying a sorbentcomposition onto a carbonaceous fuel and combusting the carbonaceousfuel to release the energy stored. The sorbent composition contains asource of calcium ion and a source of an oxidizing anion. An oxidizinganion is one that facilitates the oxidation of sulfur in thecarbonaceous fuel to sulfate and other non-volatile components that windup in the ash of the burned carbonaceous fuel. Non-limiting examples ofoxidizing anions include nitrate and nitrite anions. In a preferredembodiment, the sorbent composition contains calcium nitrite and/orcalcium nitrate. In various embodiments, the sorbent composition furthercomprises calcium bromide.

In one embodiment of the invention, the sorbent composition is appliedonto the carbonaceous fuel by applying an aqueous solution containingthe calcium and oxidizing anion onto the fuel. An effective amount ofthe sorbent composition is applied onto the carbonaceous fuel to reducethe amount of sulfur gases released into the atmosphere upon combustion.In various embodiments, up to 6% of the sorbent composition is addedonto the fuel. In various other embodiments, up to 3% or up to 1.5% ofthe sorbent composition is applied to the fuel, the percentages beingbased on the dry weight of the fuel. Higher amounts of the sorbents canbe applied as well.

In various other preferred embodiments, the sorbent composition furthercontains inorganic sources of a variety of elements shown to be helpfulin reducing the amount of sulfur gases emitted during combustion. In apreferred embodiment, the sorbent composition further contains inorganicsources of silicon, aluminum, and iron. Preferably, the sorbent furthercomprises an inorganic source of magnesium. The sorbent may containadditional insoluble inorganic sources of calcium such as calcium oxide.In a non-limiting example, the method comprises adding a powdercomposition containing silicon, aluminum, calcium, iron, and magnesiumonto the carbonaceous fuel. The elements may be provided in the form ofcomponents such as Portland cement, dolomite, and burnt dolomite. In aparticularly preferred embodiment, the method comprises applying anaqueous solution containing calcium nitrate and calcium nitrite ontoparticulate carbonaceous fuel such as coal, and adding a powdercomposition containing silicon, aluminum, calcium, iron, and magnesiumonto the wetted fuel.

In an alternative embodiment, the sorbent composition contains Portlandcement, calcium oxide, a dolomitic material selected from the groupconsisting of dolomite and burnt dolomite, and preferably analuminosilicate clay. Preferably, up to 6% by weight, up to 3% byweight, or up to 1.5% by weight of the sorbent composition is added ontothe fuel, based on the dry weight of the sorbent composition and thefuel.

The clay may be selected from a wide variety of materials. Preferredclays include calcium montmorillonite, sodium montmorillonite, kaolin,and combinations thereof. In a non-limiting example, the sorbentcomposition comprises about 20% to about 50% by weight Portland cement,about 20% to about 40% by weight calcium oxide, about 15% to about 25%by weight of the dolomitic material, and about 5 to about 15 weightpercent of the clay. An exemplary sorbent composition comprises about30% by weight Portland cement, about 40% by weight calcium oxide, about20% by weight dolomitic material, and about 10% clay.

The sorbent composition may further comprise an oxidizing salt selectedfrom the group consisting of soluble metal nitrates, soluble metalnitrites, and combinations thereof. Preferred soluble metal nitrates andnitrites include those of the alkali metals and the alkaline earthmetals. Calcium nitrate and calcium nitrite, as well as theircombination, are particularly preferred oxidizing salts.

When the sorbent composition contains oxidizing salts, the oxidizingsalts may be applied to the fuel in an aqueous solution containing thesoluble metal nitrates and nitrites discussed above. Thus, in apreferred embodiment, a solution of nitrates and/or nitrites, such ascalcium nitrate and calcium nitrite, may be applied in an aqueoussolution to the fuel, followed by application of a solid or powdersorbent composition containing Portland cement, calcium oxide, adolomitic material as discussed above, and preferably a clay asdiscussed above. Preferably, up to 6 weight percent of the sorbentcomposition is applied to the fuel. In various embodiments, up to 3weight percent of a powder composition as described above and up to 3weight percent of a liquid sorbent composition may be applied. In aparticularly preferred embodiment, up to 3 weight percent of the powdercomposition may be applied to the fuel as well as up to 1.5 weightpercent of the solids in the liquid sorbent, based on the weight of thecarbonaceous fuel.

In an alternative embodiment of applying a powder sorbent compositiononto carbonaceous fuel and combusting the fuel, the sorbent compositionapplied to the fuel contains Portland cement, at least one water solublechlorine containing inorganic compound, calcium oxide, optionally andpreferably a clay, and at least one alkali metal salt selected from thegroup consisting of sodium silicate, potassium silicate, sodiumhydroxide, potassium hydroxide, sodium oxide, and potassium oxide. Insome embodiments, it has been found that adding such powder sorbentcomposition reduces the amount of mercury in the combustion products aswell as the amount of sulfur.

The water soluble chlorine containing inorganic compound is believed toprovide chlorine in a form that interacts with mercury from the coal toform non-volatile combustion products. The water solubility of thechlorine containing compound is believed to aid in its adsorption on thecoal prior to combustion, and an intimate mixing with the mercurycontaining fuel. A wide variety of water soluble chlorine containinginorganic compounds is known. Non-limiting examples include sodiumchloride, potassium chloride, sodium chlorate, and potassium chlorate.

The sorbent composition applied to remediate mercury and sulfur containsthe individual components in amounts sufficient to effectively remove orreduce the amount of sulfur and mercury emitted from the combustionprocess. In a non-limiting exemplary embodiment, the sorbent compositioncomprises about 20 to about 30% weight Portland cement, about 2 to about5% weight inorganic chlorine compound, about 20 to about 40% weightcalcium oxide, about 20 to about 30% weight of the clay, and about 1 toabout 9% weight of the alkali metal salt. The sorbent composition mayfurther comprise at least one oxidizing salt as discussed above.Preferred oxidizing salts include calcium nitrate, calcium nitrite, andcombinations thereof. As discussed above, a preferred embodimentincludes applying a liquid sorbent containing at least one of theoxidizing salts onto the carbonaceous fuel. Before or after addition ofthe liquid sorbent, but preferably after, the powder sorbent compositiondescribed above may be mixed with the fuel.

In an alternative preferred embodiment, the liquid sorbent added to thecarbonaceous fuel contains not the oxidizing salts or anions discussedabove, but rather at least one alkali metal salt selected from the groupconsisting of potassium silicate, sodium silicate, potassium hydroxide,and sodium hydroxide. The liquid sorbent may be added to thecarbonaceous fuel either before or after the powder composition isapplied.

In some embodiments, only a liquid sorbent is applied onto the coalbefore combustion, without the necessity of adding an additional powdercomposition. In a preferred embodiment, the liquid is made up of waterand dissolved solids. The dissolved solids are made of a calcium salt orsalts selected from the group consisting of calcium nitrate, calciumnitrite, and combinations thereof, as well as other optional watersoluble components. In preferred embodiments, up to 6% weight of thesolids in the liquid sorbent is applied onto the coal. More than 6%weight may be applied, however, it is desired to keep the addition ofsolids to a minimum to avoid the need for expensive handling of ashafter combustion. In another preferred embodiment, up to 3% weight ofthe solids in the liquid sorbent is applied onto the coal. In apreferred embodiment, the liquid sorbent comprises both calcium nitrateand calcium nitrite. The liquid sorbent containing the calcium nitrateand/or calcium nitrite generally contains from about 30% to about 79%weight water. The lower water level is determined by the solubility ofthe salts, while the upper level of water is relatively arbitrary.However, the upper level of water in the sorbent composition isdetermined by the desire to efficiently add solids onto the carbonaceousfuel by spraying and other means. It has been found that other inorganiccompounds can be added to the liquid sorbents that aid in wetting of thecarbonaceous fuel. For example, calcium bromide may be added to theliquid sorbent to increase wetting.

In yet another alternative embodiment of methods of the invention, aliquid sorbent is applied onto the coal followed by application of apowder sorbent composition. The liquid sorbent may or may not containcalcium, but comprises water and a group of solids selected from thegroup consisting of soluble metal nitrates and soluble metal nitrites;calcium bromide may be added to the liquid sorbent to increase wetting.

In yet another alternative embodiment of methods of the invention, aliquid sorbent is applied onto the coal followed by application of apowder sorbent composition. The liquid sorbent may or may not containcalcium, but comprises water and a group of solids selected from thegroup consisting of soluble metal nitrates, soluble metal nitrites, andcombinations thereof. As in other embodiments, preferred nitrates andnitrites include the calcium salts. In the present embodiment, thepowder sorbent composition is one that contains at least calcium. In apreferred embodiment, the powder sorbent composition further comprisessilicon, aluminum, iron, and magnesium. In an exemplary composition, thepowder sorbent comprises Portland cement, calcium oxide, preferably analuminosilicate clay, and a dolomitic material selected from the groupconsisting of dolomite and burnt dolomite. In an alternative embodiment,the powder sorbent composition comprises Portland cement, calcium oxide,at least one water soluble chlorine containing inorganic compound,preferably an aluminosilicate clay, and at least one alkaline metal saltselected from the group consisting of potassium silicate, sodiumsilicate, potassium hydroxide, sodium hydroxide, potassium oxide, andsodium oxide. When the powder sorbent composition comprises the chlorinecontaining inorganic compounds, the compositions are especially suitablefor reducing mercury in the products of combustion of the fuel.

In addition to the methods of the invention, the invention also providesvarious combustible carbonaceous fuel compositions. The compositionscontain up to 99% weight of particulate carbonaceous fuel, and up to 10%weight based on the weight of the total combustible carbonaceous fuelcompositions of inorganic materials. In a first alternative embodiment,the inorganic materials include calcium oxide, at least one calciumcompound selected from the group consisting of calcium nitrate, calciumnitrite, and combinations thereof; an inorganic source of silicon; aninorganic source of aluminum; an inorganic source of iron; andpreferably an inorganic source of magnesium. The inorganic materials mayfurther comprise calcium bromide. In an exemplary embodiment, theinorganic materials comprise calcium nitrate, calcium nitrite, Portlandcement, calcium oxide, preferably an aluminosilicate clay, and adolomitic material selected from the group consisting of dolomite andburnt dolomite.

In one aspect of the invention, the inorganic materials are the resultof the depositing or application of the liquid and/or powder sorbentsdiscussed above.

In an alternative embodiment, the inorganic materials include Portlandcement, at least one water soluble chlorine containing inorganiccompound, an aluminosilicate clay and an alkali metal clay selected fromthe group consisting of sodium silicate, potassium silicate, sodiumhydroxide, potassium hydroxide, sodium oxide, and potassium oxide. In anexemplary embodiment, the inorganic materials comprise:

-   -   from about 20% to about 40% weight Portland cement;    -   from about 20% to about 40% weight calcium oxide;    -   from about 2% to about 5% weight of at least one water soluble        chlorine containing inorganic compound;    -   from about 20% to about 30% weight of clay; and    -   from about 1% to about 9% weight of alkali metal salts.

In various exemplary embodiments, the water soluble chlorine containinginorganic compound and the aluminosilicate clay are as described above.In this and other embodiments described above, the clay may be selectedform a number of suitable inorganic materials. Non-limiting examples ofsuitable clay include calcium montmorillonite, sodium montmorillonite,hectorite, smectites, illites, kaolin, and metakaolin.

Carbonaceous fuel for use in the invention may be used as supplied ormay be prepared for application of liquid and powder sorbentcompositions of the invention. In a preferred embodiment, coal is groundto uniform size, for example −¼″, prior to application of the sorbentcomposition. Liquid sorbents can be added directly to the pulverized orground fuel. For liquid sorbents, the addition can be made with a spraybar system that can be directed to the fuel as it passes over a belt orother transport systems. Alternatively, the liquid sorbent can be addedto the particulate fuel in a mixer. The powder sorbent compositions ofthe invention are generally applied to the particulate coal directly. Ina preferred embodiment, the particulate coal and the solid sorbentcompositions are blended with one another in mixers or similar devices.Alternatively or in addition, sorbent compositions are added into thepulverizers that pulverize the coal prior to injection.

Coal is a preferred carbonaceous fuel for use in the invention. Coalsuitable for use in the invention includes bituminous coals, anthracitecoals, and lignite coals. Other carbonaceous fuels include, withoutlimitation, various types of fuel oils, coal oil mixtures, coal oilwater mixtures, and coal water mixtures. When the carbonaceous fuel isother than a particulate coal or other fuel as described, the method ofaddition of the liquid and solid sorbents described above may be adaptedfor use with the liquid fuels according to principles known in the art.

Portland cement is an article of commerce, exemplified according to ASTMStandards as Type I, II, III, IV, or V. Portland cement consistsprincipally of di- and tri-calcium silicates. In some embodiments, it ismanufactured by firing limestone with sand in a kiln at hightemperature. The resulting clinker is crushed and ground to form acement product.

The composition of Portland cements is reported in terms of percent byweight by various metal oxides. Particularly a Portland cement containsgreater than about 60% weight calcium oxide, around 20-30% weightsilicon dioxide, and from about 2-6% weight aluminum tri-oxides, as wellas generally lesser amounts of iron (III) oxide and magnesium oxideequivalents. In some embodiments, Portland cement Type III is preferredbecause it consistently has the highest content of calcium oxide. Invarious embodiments discussed in this specification, the Portland cementwill thus be described as containing or comprising calcium oxide,silicon dioxide, aluminum dioxide, iron oxide, and magnesium oxide. Itis to be understood that such a representation is a short hand way ofdescribing the composition of Portland cement, which as discussed aboveis defined in the ASTM Standards. The Portland cement and otherinorganic components of the various sorbent compositions of theinvention will alternatively be described as containing a source ofcalcium, a source of silicon, a source of aluminum, a source of iron,and a source of magnesium.

Aluminosilicate clays are optional and preferred components in many ofthe powder sorbent compositions of the invention. When present, they maybe selected from a wide variety of materials as discussed above. Invarious embodiments, preferred clays include calcium montmorillonite,sodium montmorillonite, kaolin, and metakaolin.

In various embodiments, the sorbent compositions contain water solublechlorine containing inorganic materials. Non-limiting examples ofsoluble chlorine containing inorganic materials include the solublechlorides, chlorites, chlorates, hypochlorites, and perchlorates. In apreferred embodiment, soluble chlorine containing inorganic materialsare selected from the group consisting of alkaline earth saltscontaining the above anions and alkali metal salts containing the aboveanions. Particularly preferred are the sodium and potassium salts. Invarious embodiments, the chlorine containing inorganic material isselected from the group consisting of potassium chloride, sodiumchloride, potassium chlorate, and sodium chlorate. Mixtures orcombinations of chlorine-containing inorganic compounds may also beused.

In some embodiments, the liquid sorbents of the invention containoxidizing salts, such as the nitrates and or nitrites of calcium orother alkaline earth metals or of alkali metals. In a preferredembodiment, the oxidizing salts comprise both the nitrate and thenitrite of an alkali metal or alkaline earth metal. When both nitritesand nitrates are present, their relative proportion can range from about5:95 to 95:5. In a preferred embodiment, the proportion is about 1:1, or50:50. When the oxidizing salts contain calcium nitrate or calciumnitrite, the liquid sorbent may further preferably contain an inorganicsalt that improves the wetting ability of the calcium nitrate and thecalcium nitrate in solution. A preferred wetting agent for this purposeis calcium bromide. A solution containing 10-30% weight calcium nitrate,10-30% weight calcium nitrite, and 1-10% weight calcium bromide, theremainder being water, is sold commercially as a low temperature settingaid for concrete.

When a liquid sorbent and a powder sorbent are both to be added, therelative proportion of the powder sorbent and the liquid sorbent canrange from about 5:95 to 95:5. In a preferred embodiment, the powdersorbent compositions and the liquid sorbent compositions of theinvention are added to the carbonaceous fuel in a ratio of about 1:1.The ratio to be used depends on the relative concentration of componentsin the two sorbents, as well as the desired level of incorporation intothe combustible fuel composition of the respective components of the twosorbents.

The powder composition and the liquid compositions are added to the fuelin an effective level, keeping in mind that it is desirable to minimizethe addition of the sorbent compositions if possible to avoid thenecessity to handle or dispose of large volumes of ash. Conveniently, ithas been found that additions of up to about 6% weight of the solidmaterials (that is, no more than about 6% by weight) in the powderand/or liquid sorbent composition can lead to acceptable results. Inpreferred embodiments, up to 3% weight of the powder compositions and ofup to 3% weight of the solids in the liquid sorbent compositions areadded to the carbonaceous fuel. In some embodiments, 3% weight of apowder composition and 3% weight of a liquid composition are applied tothe fuel before burning. If the liquid composition is made of 50% solidsthis corresponds to adding 1.5% weight of the solids of the liquidcomposition onto the carbonaceous fuel.

When both are added, the order of addition of liquid sorbentcompositions and powder sorbent compositions may be varied to achievethe desired results. In many embodiments, it is preferred to add theliquid sorbent composition to the fuel before adding the powder sorbentcomposition. This has the tendency to improve adhesion of the powdercomponents, which are applied onto a wetted fuel.

Dolomitic material as used in the invention is a calcium and magnesiumcarbonate material. It is commercially available as dolomite or, in analternative embodiment, as so-called burnt dolomite. Burnt dolomite isthe product of heating or calcining the dolomite material. Burntdolomite is believed to be a combination of magnesium oxide and calciumoxide material. In various embodiments, the addition of dolomiticmagnesium is believed to hold the cell structure of the silicate andaluminosilicate material open for improved sulfur absorption. In apreferred embodiment, dolomitic magnesium is provided in addition to themagnesium that is provided in the Portland cement.

Use of the methods and compositions of the invention results in burningof coal and of other carbonaceous fuels with reduced emission ofvolatile sulfur gases or harmful compounds into the atmosphere uponcombustion. In addition to the deleterious health and environmentaleffect of emitted sulfur gases, another important concern to utilitiesand other coal consumers is the regulatory scheme around the emission ofsulfur oxides. Specifically, current regulations in the United Statesrequire that if more than 1.2 pounds (about 550 g) of sulfur dioxide isreleased into the atmosphere for every million BTU of coal that isburned, the coal facility operator must purchase so-called pollutioncredits or mitigate the release of sulfur gases below that level.Depending on the amount of sulfur in the coal, such pollution creditscan constitute a major expense of operation. Accordingly, it would bebeneficial to reduce the emission of sulfur below that level. Coal thatcan be burned in power plants and other facilities with concomitantrelease of less than 1.2 lbs of sulfur dioxide per million BTUs iscalled in the United States as compliant coal. In various embodiments,the compositions and methods of the invention result in the productionof compliant coal that can be burned to generate electricity and forother uses without harming the environment or incurring liability forregulatory pollution costs.

The invention has been described with respect to various preferredembodiments. Further non-limiting embodiments are given in the Examplesthat follow.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

EXAMPLES Example 1 Powder Composition 1

A powder composition is mixed that contains 30% weight Portland cement,40% weight calcium oxide, 20% weight dolomite, and 10% weight calciummontmorillonite.

Example 2

Minkota lignite coal having a raw sulfur content of approximately 2.0%weight, an ash content of approximately 16% weight, and a moisturecontent of approximately 30% is ground to −¼ inch and mixed with eitherno sorbent (Comparative Example 1), a sorbent consisting solely ofPortland cement (Comparative Example 2) or a sorbent consisting ofpowder sorbent 1 of Example 1. Addition of sorbent material to the coalis 6% weight

For the compositions containing the sorbents, the respective sorbentcompositions and the coal are mixed in a Hobart Mixer with a verticalpaddle at 60-90 RPM for two minutes. Then the coal samples arecombusted. Total sulfur in the samples is determined according to ASTMD-4239, while the total sulfur sorbed in the ash is determined accordingto ASTM D-5016. According to data in the table, burning of the raw coal(Comparative Example 1) results in 61% of the sulfur being sorbed in theash, while addition of Portland cement as a sorbent (Comparative Example2) increases the percent sorbed to 71%. The coal sample (shown asExample 2) having the powder sorbent of Example 1 shows 79.9% of sulfursorbed in the ash.

% Sulfur in % Sulfur Sample sorbed in ash Comparative Ex. 1 2.07 61.0Comparative Ex. 2 2.00 71.0 Example 2 1.95 79.9

Example 3a Powder Composition 2

A powder sorbent composition is mixed that contains 30% weight Portlandcement, 3% weight sodium chloride, 33% weight calcium oxide, 25% weightmetakaolin, 4.5% weight anhydrous potassium silicate, and 4.5% weightpotassium hydroxide powder.

Example 3b Liquid Sorbent Composition 1

Liquid sorbent composition 1, commercially available from Grace Chemicalunder the DCI tradename, contains 10-15% calcium nitrite, 10-25% calciumnitrate, 1-3% calcium bromide, the remainder being water.

Example 4 Illinois Crown III Bituminous Coal

The coal of Example 4 is Illinois Crown III bituminous coal containingapproximately 4% weight sulfur, 10.6% weight ash, and 15.6% weightmoisture. The coal is ground to minus one quarter inch and combined withvarious sorbents as provided in the table. The coal is prepared and thesorbents are applied as in Example 2. Percent sulfur in the sample isdetermined according to ASTM D-4239, while total sulfur reporting to ashis determined by ASTM D-5016. The percent total sulfur in the emissionsis determined by the difference.

For this high sulfur coal, only 3.4% of the total sulfur reports to theash upon combustion without any sorbent (Comparative Example 3). WhenPortland cement alone is used as the sorbent composition, only 13% ofthe total sulfur reports to ash (Comparative Example 4). When CompositePowder 2 is added at a 6% weight level, the percent total sulfurreporting to ash increases to 44.9% (Example 4a). When 3% weight of thePowder Composition 2 and 3% weight of the liquid sorbent 1 from Example3a and 3b, respectively, are added as sorbent to the coal, the percenttotal sulfur reporting to ash increases to 50.5%.

% Total Sulfur % Sulfur % Total Sulfur In Sample in Emissions Reportingto Ash Comparative Ex. 3 4.17 96.51 3.4 Comparative Ex. 4 4.06 87.0 13.0Example 4a 3.84 55.15 44.9 Example 4b 3.84 49.5 50.5

Example 5

Freeman Crown III coal is used as in Example 4. Untreated coal is burnedand the amount of chlorine released into the atmosphere determined to be0.19% (Comparative Example 5). When coal treated with 3% weight powdercomposition 1 and 3% weight liquid composition 1 is burned (Example 5),the amount of chlorine released into the atmosphere is 0.13%.

Example 6

Freeman Crown III coal is again used. When untreated coal is burned, theash remaining after combustion contains 0.001% weight mercury(comparative example 6). When coal is treated with 3% by weight each ofpowder composition 2 and liquid composition 1, and combusted, the ashremaining after combustion contains 0.004% mercury.

Although the invention has been described above with respect to variouspreferred embodiments, it is to be understood that the invention is notlimited to the disclosed embodiments. Rather, variations andmodifications that would occur to one of skill in the art upon readingthe disclosure are also intended to be within the scope of theinvention, which is limited and defined only by the appended claims.

What is claimed is:
 1. A method of burning coal to capture sulfur in acalcium and ceramic based matrix, the process comprising applyingremediation materials as a powder onto coal, combusting the coal, andmeasuring the amount of sulfur in the ash resulting from the combustion,wherein the remediation materials comprise clay and iron.
 2. The methodaccording to claim 1, wherein the clay is selected from calciummontmorillonite, sodium montmorillonite, hectorite, smectites, illites,kaolin, and metakaolin.
 3. The method according to claim 1, wherein theash comprises a higher level of sulfur than ash resulting from coalburned without the applied remediation materials.
 4. The methodaccording to claim 1, wherein the clay is kaolin or metakaolin.